How to build a relatively inexpensive, reliable, 'powerful' 2.0 8v.

[911_fan]

[B4S]

I've noticed that too.. Some OBD1 cars are odd. I've also seen 96's with OBD1 ecu's.. Odd.

In Canada, our Mk3s didn't switch to OBD2 until mid-1997. OBD1 was from 93-mid 97 up here .

[Hurt]

In Canada, our Mk3s didn't switch to OBD2 until mid-1997. OBD1 was from 93-mid 97 up here .

That's crazy.

[B4S]

Tell me about it, but it works out well. The emissions testing in my area is cake to pass if you're OBD1 and older, and there are a LOT of OBD1 'project' cars around . OBD2 is where it gets difficult to modify anything, since the stock ECU has to remain in place. Chipping is an option, but I can't justify the cost of an aftermarket chip vs. the cost of MS3 (at least in OBD2 anyway, I chip my own OBD1 ).

BTW: If anyone wants more 'freedom' with their OBD1 cars, it's super easy to write your own chips for the ABA. If you have an ebay chip burner ($16) and some chips ($5), you can custom tune the stock ecu like megasquirt. Custom dyno tuning anyone? .

[911_fan]

Canada didn't adopt obd2 until 1996...MY1997.

[Hurt]

I'm going to get my Daily 8v dyno'd sometime this week, hopefully, if I can ever go back home to CT! I've been on business in CA all week! I'm hoping for at least 130whp.

98 Jetta 2.0
*my DAILY DRIVER*
[276* TT cam set to +4 advance ( adds low end tq, no high end loss..)
3 angle valve job OBD1 head with LW lifters and HD valve springs
decked/Milled .040"
90mm HG (+ .5 compression)
TT non-aluminum cam gear (thanks for the advice, travis!)
USRT LRI manifold
MK4 exhaust manifold w/ TT race DP
2.5" Custom Mandrel Bent exhaust w/ 2 Magnaflow mufflers and a 20" resonator. (quiet <3)
MSD ignition set up w/ 8.5mm wires
Battery moved to the trunk
H&R Ultra Low's 20" ftg front, 20.5" ftg rear
195/50/R15 15x7" Phone Dials. (kumho Ecsta tires)
BBM 6 speed 020 with a peloquin LSD. (so worth the money!)
25mm front sway bar
28 rear sway bar
front and rear tie bars
etc..]

I'm planning on swapping this powertrain into a MK2 Jetta coupe I just picked up for 500 bucks. It is already wired for an OBD2 ABA (owned by a kid who blew the engine with nitrous , so it'll be a nice, easy swap.

[Hurt]

Well, a plan fell into my lap. I found a nice b3 wagon in south MA, sitting on the side of someone's house. It had been hit really hard in the rear. I asked if it was for sale, the guy said I can have it for 500 bucks. It only had 90k miles on the original 9a 2.0 16v engine! I had it towed home within a few hours.

My buddy's little brother got his first car last month - a MK3 Golf Wolfsburg which has a MINT interior and barely any rust - which he beat on til the timing belt snapped (The belt was ORIGINAL and the car had ~180k on it). The head is shot, and so is the tranny. I bought it for 300 dollars yesterday. I will be swapping in the passat's 2.0 16v 9a and the CR tranny in the Golf, and possibly daily driving it. I just ordered nearly 5 figures of parts for the Golf. If anyone wants to know the parts I ordered, let me know, and I'll PM you the list.

[2.slowduo]

nice find on all the cheap cars, 9a mk3 should be a blast

would love to hear how your trip to the dyno went on that 8v set up

I would think 130whp would be a pretty tame estimate since I'm at 120whp with a 268 and stock mani's. similar deck job,p&p and 3 angle V job
I'm also curious about the non aluminum cam gear? whats wrong with the alum. one?

[Hurt]

I'm also curious about the non aluminum cam gear? whats wrong with the alum. one?

The TT non-aluminum cam gear is basically just a stock cam gear with the inside removed and replaced with an adjustable center. The problem with the aluminum ones is that the teeth are too soft and they'll actually start to get sharp and ruin your timing belt.

[Jh0104]

good luck on the dyno

[Hurt]

nice find on all the cheap cars, 9a mk3 should be a blast

would love to hear how your trip to the dyno went on that 8v set up

I would think 130whp would be a pretty tame estimate since I'm at 120whp with a 268 and stock mani's. similar deck job,p&p and 3 angle V job

Thanks! I hope so, too. The LRI made a big difference!

good luck on the dyno

Thanks, bud!

[Hurt]

135WHP on the dyno. The fastback put down much bigger numbers, though, at 450WHP.

[B4S]

Nice!

[911_fan]

Post the sheet. I want to compare it to my 135 run.

[Hurt]

Post the sheet. I want to compare it to my 135 run.

Will do ASAP. I gotta scan it, or have the dyno-operator email it to me. I'm thinking we should be pretty similar, considering we had very similar mods, right? I think the only thing really different I have is the 90mm HG and maybe bigger exhaust? The LRI I bought (after reading your comparison thread, thanks! ) made a huge difference. Sounds like my old ITB b18 Honda!

[911_fan]

que?

decked/Milled 040"
90mm HG (+5 compression)

[Hurt]

que?

Oops. That's supposed to say +0.5. It's vended out of BFI, but I got mine at SummitRacing, I believe. They have good deals on gasket sets.

[911_fan]

Gotcha, so about 11:1 five or take

[Hurt]

Gotcha, so about 11:1 five or take

I'm not entirely sure. I never asked my friend for the paperwork for the head, but he does very good jobs. I have had 5 or 6 cylinder heads ported/decked/milled by him. Of course, the exhaust manifold and intake manifold gasket matching was done by me, because I am not THAT inept. I don't have any issues with this engine, really. When I bought it, I replaced pretty much everything. I think 135whp is a pretty good number, though, considering I beat my buddies EM1 civic Si B16a2 160hp 111tq from the factory and he has i/h/e, and our cars weigh about the same. (racing is done on a track, don't street race, people!". He has alot of suspension work, though. He handles a bit better. When I had Koni Yellows and Neuspeed Race springs, it handled amazingly! All in all, I daily this car every single day, and take it to 7,000 RPM occasionally.

[bigteal]

Actually drove mine last night. I forgot how much fun it is
Hoping to hit the dyno soon, got to take care of the cel first ( maf issues). 130-135whp and I'll be happy with it.

[Hurt]

Actually drove mine last night. I forgot how much fun it is
Hoping to hit the dyno soon, got to take care of the cel first ( maf issues). 130-135whp and I'll be happy with it.

Sounds good, bud. I've been busy working on my 9a MK3 project.

[Hurt]

I have been meaning to make a few little updates, but I have been busy working on a good friends' 95 Golf Sport 2.0 8v. He's new to the VW scene, he has been a "Honda-boy" since High school and that he hated VW's just because they are VW's. ..

Unfortunately, it was subjected to a ton of abuse by the PO!
It had a 3aRacing fart-can on the end of a 2" crush bent exhaust, a dented cone filter stuck on the end of the MAF, a "short shifter" (which was a cut shift selector rod) and PURPLE tints.

I spent the day removing all these horrible modifications with him, and we put on a TT 2.5" catback with a flowmaster muffler, a 42DD testpipe, a Eurosport cool-flow intake, my old Autotech 270* cam, and soldered in my old GIAC cam chip. We put on a SS 60/40 cupkit, as well as removing the tint. We put on a CL lip, too, and some GTI smoked tails. (All of these parts were sitting around my shop.. I have a shed full of VW parts ) Unfortunately, it's riding on OEM flyers for a little bit. He says it's much better than any Honda he has driven except for his old GS-R.

You ever get that feeling that you took someone over from the land of ignorance and idiocy and put them in a "real car" and educate them? It's such a great feeling.

[OC80]

hey guys I have a question about my car I have a 1996 golf and it had a intake, exhaust, and a chip. I added a 260 TT cam. Should I bother getting a new chip? like a bfi one? help is appreciated!

[CasuallyWreckless]

a matchin chip for you cam is always the best route if you have the money do it mr. hurt.. what else u got layinaround lol

[Alingarhs]

Wondered this, I've got a Neuspeed supercharger on the car with a 2.25 Magnaflow cat-back.
Was planning on getting a high flow cat and headers. But do you think the headers will do much with this setup or just stick with the factory manifold and downpipe?

[911_fan]

For the money you would spend on those, you can get an ecu/MAF tune upgrade from C2 and get more power. The tune used by Neuspeed runs on the lean side. The c2 tune uses a better tune with upgraded maf and injectors to get more power out of your charger. Couple that with a bigger cam, and you are lookin at 10-15 more whp easy.

[Hurt]

hey guys I have a question about my car I have a 1996 golf and it had a intake, exhaust, and a chip. I added a 260 TT cam. Should I bother getting a new chip? like a bfi one? help is appreciated!

I'd get a cam profile chip. From your other threads I gather that your chip is from TT. You can contact them and send the chip back to get reburnt for the cam for a cheap rate which is way better than spending another 100 bucks for a cam chip!

a mr. hurt.. what else u got layinaround lol

Too many VW parts. I own a bit of property where it's secluded and I keep old VW's hanging around (after builds, or engine swaps). My buddies call it "the dub graveyard".

Wondered this, I've got a Neuspeed supercharger on the car with a 2.25 Magnaflow cat-back.
Was planning on getting a high flow cat and headers. But do you think the headers will do much with this setup or just stick with the factory manifold and downpipe?

High flow cats are useless, really. If you want to gain a few more HP get a 268/260 cam from TT, get their Race DP (it deletes the CAT) and mate that to a MK4 AEG exhaust manifold. You could go to C2 and order 42# injectors, a bigger MAF, and their generic boost tune, too, if you'd like. Then you can crank up the boost. Problem with the neuspeed S/C is that it's so difficult to add a front mount and you're prone to heat soak. You might want to get a bigger exhaust, too, since the 2.25" will choke the engine at high RPM's if you do get the cam upgrade.

[Audiooutlaw]

What is the vacuum thing below my head? That when I remove the plug it almost kills the motor. And also on hard acceleration it kinda dies a little then goes

[Audiooutlaw]

Because I have my mk4 intake top/bottom and fuel rails. And if I have to have it I can't donmy conversion

[Hurt]

What is the vacuum thing below my head? That when I remove the plug it almost kills the motor. And also on hard acceleration it kinda dies a little then goes

Because I have my mk4 intake top/bottom and fuel rails. And if I have to have it I can't donmy conversion

Post a picture, I'm really not sure what you mean, unless it's the SAI system? (the pump that has a line going to the side of the airbox)

[Hurt]

Well, guys, I did it again.. I bought a bone stock 2.0 Golf Sport. I couldn't pass it up! It was only 300 bucks. Has a blown engine but good sport plaid seats, interior. Some dings on the exterior, not too much rust. I may end up putting a low-mile 8v in it to replace the blown ABA in it. I may end up slapping on my old BBM lysolm kit.. Dang it. Money pit, money pit, money pit! Did I mention it's Surf Green?
Here's a few pictures from the seller:
A few dings here and there..

[MahTrek=]]

Great find!!!!

[Alingarhs]

Love the seats

[Hurt]

I already have a motor/trans lined up to go into the GTI.. It's just a plain OBD1 engine and 020 trans. I, well, spent some money on TT's website today.. I gave all my Golf parts to my friend for his..

Had to buy new stuff.

[911_fan]

So Im confused....

Is this a How-to/DIY, or is this now your personal build thread / blog?